TP 301 04

TP-301-04
January 17, 2007
U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
LABORATORY TEST PROCEDURE
FOR
FMVSS 212
Windshield Mounting
FMVSS 219
Windshield Zone Intrusion
FMVSS 301
Fuel System Integrity
(Passenger Cars, MPV’s and Light Trucks with GVWR’s under 4,536 kg)
SAFETY ASSURANCE
Office of Vehicle Safety Compliance
Room 6111, NVS-220
400 Seventh Street, SW
Washington, DC 20590
OVSC LABORATORY TEST PROCEDURE NO. 301
TABLE OF CONTENTS
PAGE
1. PURPOSE AND APPLICATION .................................................................................... 1
2. GENERAL REQUIREMENTS ........................................................................................ 2
3. SECURITY ..................................................................................................................... 2
4. GOOD HOUSEKEEPING............................................................................................... 3
5. TEST SCHEDULING AND MONITORING..................................................................... 3
6. FACILITY AND EQUIPMENT......................................................................................... 3
7. GOVERNMENT FURNISHED PROPERTY (GFP) ........................................................ 8
8. CALIBRATION OF TEST INSTRUMENTS .................................................................... 9
9. PHOTOGRAPHIC DOCUMENTATION ......................................................................... 10
10. DEFINITIONS................................................................................................................. 16
11. PRETEST REQUIREMENTS......................................................................................... 19
12. TEST EXECUTION ........................................................................................................ 20
13. TEST DATA DISPOSITION ........................................................................................... 31
14. REPORTS ...................................................................................................................... 31
14.1. MONTHLY STATUS REPORTS ........................................................................ 31
14.2. APPARENT NONCOMPLIANCE ....................................................................... 32
14.3. FINAL TEST REPORTS..................................................................................... 32
14.3.1. COPIES .................................................................................................. 32
14.3.2. REQUIREMENTS................................................................................... 32
14.3.3. FIRST THREE PAGES........................................................................... 33
14.3.4. TABLE OF CONTENTS.......................................................................... 37
15. DATA SHEETS .............................................................................................................. 41
16. FORMS .......................................................................................................................... 58
APPENDIX 1, Anti-Siphoning Device for Alcohol Fuel Vehicles .................................... 64
APPENDIX 2, Modified FMVSS 301 Test, Rear Impact Only ........................................ 66

REVISION CONTROL LOG
FOR OVSC LABORATORY
TEST PROCEDURES
TP-301
(Fuel System Integrity)
TEST PROCEDURE FMVSS 301
REV. EFFECTIVE DESCRIPTION

No. DATE AMENDMENT DATE
00 04/26/89 No Revision 04/26/89 Original release signed by O.D.
01 3/28/94 3/28/94 Add 2 appendices
02 11/8/94 11/8/94 Add lateral camera requirements
03 2/28/03 63FR28922 5/27/99 Conversion to metric and minor revisions
04 1/17/07 1/17/07 Reference 214 for lateral impact
05
06
07
08
09
10
TP-301-03 Page 1
1. PURPOSE AND APPLICATION
The purpose of the standard is to reduce deaths and injuries occurring from fires
that result from fuel spillage during and after motor vehicle crashes. The standard
applies to passenger cars, and to MPVs, trucks, and buses that have a GVWR of
4,536 kg or less. It also applies to school buses with a GVWR greater than 4,536
Kg. TP-301-SB covers these school buses.
The Office of Vehicle Safety Compliance (OVSC) provides contracted laboratories with
Laboratory Test Procedures as guidelines for obtaining compliance test data. The data
are used to determine if a specific vehicle or item of motor vehicle equipment meets the
minimum performance requirements of the subject Federal Motor Vehicle Safety
Standard (FMVSS). The purpose of the OVSC Laboratory test procedures is to present a
uniform testing and data recording format, and provide suggestions for the use of specific
equipment and procedures. If any contractor views any part of an OVSC Laboratory test
procedure to be in conflict with a Federal Motor Vehicle Safety Standard or observes
deficiencies in a Laboratory test procedure, the contractor is required to advise the
Contracting Officer's Technical Representative (COTR) and resolve the discrepancy prior
to the start of compliance testing.
Every Contractor shall submit a detailed test procedure to the COTR before
initiating the compliance test program. The procedure shall include a step-by-step
description of the methodology to be used. The contractor’s test procedure shall
contain a complete listing of test equipment with make and model number and a
detailed check-off sheet. The list of test equipment shall include instrument
accuracy and calibration dates. All equipment shall be calibrated in accordance
with the manufacturer’s instructions. There shall be no contradictions between the
Laboratory Test Procedure and the contractor’s in-house test procedure. Written
approval of the in- house test procedures shall be obtained from the COTR before
initiating the compliance test program.
The OVSC Laboratory TPs are not intended to limit or restrain a contractor from
developing or utilizing any testing techniques or equipment, which will assist in
procuring the required compliance test data. These Laboratory Test Procedures
do not constitute an endorsement or recommendation for use of any product or
method. However, the application of any such testing technique or equipment is
subject to prior approval of the COTR.
NOTE: The OVSC Laboratory Test Procedures, prepared for the limited purpose
of use by independent laboratories under contract to conduct compliance tests for
the OVSC, are not rules, regulations or NHTSA interpretations regarding the
meaning of a FMVSS. The Laboratory Test Procedures are not intended to limit
the requirements of the applicable FMVSS(s). In some cases, the OVSC
Laboratory Test Procedures do not include all of the various FMVSS minimum
performance requirements. Recognizing applicable test tolerances, the
Laboratory Test Procedures shall specify test conditions that are less severe than
the minimum requirements of the standard. In addition, the Laboratory Test
Procedures may be modified by the OVSC at any time without notice, and the
COTR may direct or authorize contractors to deviate from these procedures, as
long as the tests are performed in a manner consistent with the standard itself and
TP-301-03 Page 2
within the scope of the contract. Laboratory Test Procedures may not be relied
upon to create any right or benefit in any person. Therefore, compliance of a
vehicle or item of motor vehicle equipment is not necessarily guaranteed if the
manufacturer limits its certification tests to those described in the OVSC
Laboratory Test Procedures.
2. GENERAL REQUIREMENTS
FMVSS 212
When the vehicle traveling longitudinally forward at any speed up to and including 48.3
KM/H impacts a fixed collision barrier that is perpendicular to the line of travel of the
vehicle, the windshield mounting of the vehicle shall retain not less than 50 percent of the
portion of the windshield periphery on each side of the vehicle longitudinal centerline for
vehicles equipped with front occupant automatic restraints, and 75 percent of the
windshield periphery for vehicles not equipped with automatic restraints.
FMVSS 219
When the vehicle traveling longitudinally forward at any speed up to and including 48.3
KM/H impacts a fixed collision barrier that is perpendicular to the line of travel of the
vehicle, no part of the vehicle outside the occupant compartment, except windshield
molding and other components designed to be normally in contact with the windshield,
shall penetrate the protected zone template to a depth of more than 6.4 mm, and no such
part of a vehicle shall penetrate the inner surface of that portion of the windshield, within
the daylight opening (DLO), below the protected zone.
FMVSS 301 — FUEL SPILLAGE — BARRIER CRASH
This standard applies to passenger cars, and to MPVs, trucks and buses that use
fuel with a boiling point above 0°C. Fuel spillage in any fixed or moving barrier
crash test shall not exceed 28 g from impact until motion of the vehicle has
ceased, and shall not exceed a total of 142 g in the 5- minute period following
cessation of motion. For the subsequent 25-minute period, fuel spillage during
any 1 minute interval shall not exceed 28 g.
FMVSS 301 — FUEL SPILLAGE — ROLLOVER
This standard applies to passenger cars, and to MPVs, trucks and buses that use
fuel with a boiling point above 0°C. Fuel spillage in any rollover test, from the
onset of rotational motion, shall not exceed a total of 142 g for the first 5 minutes
of testing at each successive 90° increment. For the remaining testing period, at
each successive 90° increment, fuel spillage during any 1-minute interval shall not
exceed 28 g.
3. SECURITY
The contractor shall provide appropriate security measures to protect the OVSC
test vehicles and Government Furnished Property (GFP) such as test dummies
from unauthorized personnel during the entire compliance testing program. The
TP-301-03 Page 3
3. SECURITY….continued
contractor is financially responsible for any acts of theft and/or vandalism, which
occur during the storage of test vehicles and GFP. Any security problems, which
arise, shall be reported by telephone to the Industrial Property Manager (IPM),
Office of Contracts and Procurement, within two working days after the incident. A
letter containing specific details of the security problem shall be sent to the IPM
(with copy to the COTR) within 48 hours.
The contractor shall protect and segregate the data that evolves from compliance testing
before and after each vehicle test. No information concerning the vehicle safety
compliance-testing program shall be released to anyone except the COTR, unless
specifically authorized by the COTR or the COTR's Branch Chief or Division Chief.
NOTE: NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL DIRECTLY

INVOLVED IN THE COMPLIANCE TESTING PROGRAM OR OVSC PERSONNEL,
SHALL BE ALLOWED TO WITNESS ANY VEHICLE COMPLIANCE TEST UNLESS
SPECIFICALLY AUTHORIZED BY THE COTR.
4. GOOD HOUSEKEEPING
Contractors shall maintain the entire vehicle compliance testing area, test dummy storage
area, test fixtures and instrumentation in a neat, clean and painted condition with test
instruments arranged in an orderly manner consistent with good test laboratory
housekeeping practices.
5. TEST SCHEDULING AND MONITORING
The contractor shall submit a vehicle test schedule to the COTR prior to conducting the
first compliance test. Tests shall be completed as required in the contract.
Scheduling of vehicle tests shall be adjusted to permit vehicles to be tested to other

FMVSSs as may be required by the OVSC. All vehicle compliance testing shall be
coordinated with the COTR in order to allow monitoring by the COTR and/or other OVSC
personnel if desired.
6. FACILITY AND EQUIPMENT
6.1 IMPACT TEST FACILITY
At a minimum, the impact test facility shall consist of a tow road, test pad area,
fixed collision barrier (for frontal and oblique impact tests) and underground
photographic pits. The facility shall be equipped with a tow and guidance system,
test abort system, impact speed measurement and speed control systems and a
static rollover device.
TP-301-03 Page 4
6. TEST DATA DISPOSITION ....continued
TYPICAL BARRIER IMPACT

TEST FACILITY
TEST
CONTROL
CENTER
TOW CABLE
DRIVE
BUILDING
CONCRETE
TEST PAD TEST VEHICLE
PREPARATION
AREA
MONORAIL
CONCRETE
BARRIER
PHOTO PIT
COVERED WITH
CLEAR PLASTIC
6.2 IMPACT SPEED MEASUREMENT SYSTEM
Test vehicle or moving barrier impact speed or velocity shall be measured by 2

timing devices (photocells, break wires, laser beams, etc.) located within 1.5
meters of the impact plane. Both timing devices shall be accurate within plus or
minus 0.08 km/h and shall be calibrated by an instrument traceable to the National
Institute of Standards And Technology. The impact speed shall be permanently
recorded (photograph of the digital readout from the timing device will suffice). A
third timing device shall be placed at a sufficient distance from the impact plane for
monitoring the speed of the test vehicle or moving barrier and permit a test abort if
necessary.
6.3 MOVING BARRIER
The contractor shall have a moving barrier to conduct lateral and rear impact tests.
The moving barrier shall consist of:
1. A common carriage constructed in accordance with Figure 1 of

571.301, which is symmetrical about a vertical plane containing its
longitudinal axis.
2. A solid non-steerable front axle and fixed rear axle attached directly
to the frame rails with no springs or other type suspension system on
any wheel.
3. An impact surface that is a vertical, rigid, flat rectangle, 1981 mm (78

inches) wide and 1524 mm (60 inches) high, with its lower edge
TP-301-03 Page 5
horizontal and 127 mm (5 inches) above the ground surface. The

impact surface shall be faced with a sheet of 19 mm (0.75 inch) thick
exterior plywood, 1981 mm (78 inches) wide and 1524 mm (60
inches) high.
4. A braking device capable of stopping it.
5. Mounting brackets necessary to accommodate an overhead camera

and abort brake system.
6. A weight distribution of 408.2 ± 11.3 kg at each rear wheel and 499 ±

11.3 kg at each front wheel when equipped with camera and abort
system
7. Pneumatic tires on all wheels, P205/75R15, inflated to 200 +/- 21

kPa.
NOTE: The plywood shall be replaced as necessary during the compliance testing
program.
TP-301-03 Page 6
Fig 1 - COMMON CARRIAGE FOR MOVING BARRIERS

4
GROUND SURFACE
FRONT VIEW
4
GROUND SURFACE
SIDE VIEW
A - WHEELBASE
BALLAST 1 2 BALLAST
45 ° B
C
TREAD
P R
D
Q
3 G F
H
J
M K
L
N
E
TOP VIEW
NOTES:
DIMENSIONS SHOWN IN TABLE ON NEXT PAGE
1. OUTER FRAME 6.0 x 2.0 x 0.19 in. (152 x 51 x 5 mm) STEEL TUBING, TWO PIECES WELDED
TOGETHER FOR A 12.0 in. (305 mm) HEIGHT.
2. BALLAST TIE DOWNS.
3. ALL INNER REINFORCEMENTS AND FRAME GUSSETS OF 4.0 x 2.0 x 0.19 in. (102 x 51 x 5 mm)
STEEL TUBING.
4. REINFORCE AREAS FOR BOLTING ON FACE PLATES.
TP-301-03 Page 7
DIMENSIONS FOR COMMON CARRIAGE FOR MOVING BARRIERS

LETTER INCHES MILLIMETERS
A 120.0 3048
B 60.0 1524
C 42.0 1067
D 21.0 533
E 144.0 3658
F 15.0 381
G 16.0 406
H 12.0 305
J 24.0 610
K 60.0 1524
L 84.0 2134
M 22.0 559
N 120.0 3048
P 16.0 406
Q 12.0 305
R 6.0 152
Note - Dimensions shall be within 5% of the specifications listed above
6.4 PHOTOGRAPHIC PIT
For FRONTAL and REAR impact tests, to permit underbody film coverage, the test
pad area shall be equipped with a photographic pit. The pit shall be covered with
plastic, Plexiglas, etc. strong enough to preclude any part of the vehicle from
collapsing below ground level during the impact.
6.5 STATIC ROLLOVER DEVICE
The rollover device shall be capable of rotating the impacted test vehicle about its
longitudinal axis with the axis kept horizontal, to each successive increment of 90°,
180°, and 270° at a uniform rate, with 90° of rotation taking place in any time
interval from 1 to 3 minutes and holding in position up to 5 minutes.
6.6 WEIGHING SCALES
The scales used to weigh the test vehicle shall be accurate to within 0.1%.
6.7 TEST SURFACE AND TEST PAD AREA
The concrete surface upon which the vehicle is tested is level, rigid, and of uniform
construction with a skid number of 75 when measured in accordance with
American Society of Testing and Materials Method E: 274-65T at 64 km/h, omitting
water delivery as specified in paragraph 7.1 of that method.
TP-301-03 Page 8
6.8 TOW ROAD
The tow road surface shall be straight, level, smooth and of uniform construction.
The tow road shall be of sufficient length to allow stabilization of speed and
attitude of the moving barrier (in lateral or rear impact tests) or the test vehicle (in
frontal or oblique impact tests).
6.9 TOW AND GUIDANCE SYSTEM
The tow and guidance system shall be capable of ensuring that the moving barrier
(in lateral or rear impact tests) or the test vehicle (in frontal or oblique impact tests)
impact at the proper angle and within the speed tolerances specified for each type
of test. The moving barrier or test vehicle shall be continuously towed up until it
reaches 610 mm to 152 mm from impact. The tow cable attachment device shall
release from the tow cable within the tolerance window. The velocity
measurement shall be taken after cable release.
6.10 TEST ABORT SYSTEM
Test vehicles and the moving barrier shall be equipped with onboard brake abort
systems. For rear impact compliance tests, the target vehicle and the moving
barrier brake systems shall not be activated until after the final vehicle/barrier
separation has occurred unless the vehicle rear wheels are jammed by deformed
sheet metal and the vehicle remains against the moving barrier's face throughout
the braking process. Moving barrier brakes shall be applied in advance of test
vehicle brakes in order to preclude secondary impacts. The OVSC recommends
the use of redundant brake abort systems.
.
7. GOVERNMENT FURNISHED PROPERTY (GFP)
GFP shall consist of anthropomorphic test devices (test dummies) and test
vehicles.
TEST DUMMIES
NHTSA’s Dummy Management will furnish an adequate number of Part 572 50th-
percentile adult male test dummies to the contract laboratory. These dummies
shall be stored in an upright seated position in a secured area which is
temperature controlled between 10°C and 30°C. The contractor shall inspect the
dummies for component damage after each crash test usage. The contractor shall
keep the NHTSA Dummy Management informed of the need for dummy
replacement components.
TEST VEHICLES
The Contractor shall be responsible for accepting test vehicles from either new car
dealers or vehicle transporters. In both instances, the contractor acts in the
TP-301-03 Page 9
7. GOVERNMENT FURNISHED PROPERTY (GFP) ....continued
OVSC's behalf when signing an acceptance of test vehicles. The contractor shall
complete a thorough visual inspection of test vehicle prior to acceptance. The
contractor shall complete a Vehicle Condition Report form and fax to the COTR
within 24 hours after a vehicle has been delivered (see section 16, FORMS).
In addition to the above, the Contractor shall check for any damage, which may
have occurred during transit. The Contractor shall document the inspection and
report any problems to the COTR. This notification shall occur prior to preparation
of the vehicle for testing.
8. CALIBRATION OF TEST INSTRUMENTS
Before the contractor initiates the safety compliance test program, the contractor
shall implement and maintain a test instrumentation calibration system in
accordance with ISO-10012-1, Calibration System Requirements. The calibration
system shall be set up and maintained by the contractor as follows:
A. Standards for calibrating the measuring and test equipment shall be stored
and used under appropriate environmental conditions to assure their
accuracy and stability.
B. All measuring instruments and standards shall be calibrated by the

contractor, or a commercial facility, against a higher order standard at
periodic intervals NOT TO EXCEED 12 MONTHS! Records, showing the
calibration traceability to the National Institute of Standards and Technology
(NIST), shall be maintained for all measuring and test equipment.
C. All measuring and test equipment and measuring standards shall be

labeled with the following information:
(1) Date of calibration
(2) Date of next scheduled calibration
(3) Name of the technician who calibrated the equipment
D. A written calibration procedure shall be provided by the contractor which

includes as a minimum the following information for all measurement and
test equipment:
(1) Type of equipment, manufacturer, model number, etc.
(2) Measurement range
(3) Accuracy
(4) Calibration interval

TP-301-03 Page 10
8. CALIBRATION OF TEST INSTRUMENTS....continued
(5) Type of standard used to calibrate the equipment (calibration

traceability of the standard shall be evident)
E. Records of calibration for all test instrumentation shall be kept by the

contractor in a manner, which assures the maintenance of established
calibration schedules. All such records shall be readily available for
inspection when requested by the COTR. The calibration procedure shall
be approved by the COTR before the test program commences.
9 PHOTOGRAPHIC DOCUMENTATION
9.1 COLOR PHOTOGRAPHS
The contractor shall take pretest and post test still color photographs. The
photographs shall be 8 x 10 inches, and properly focused for clear images. A tag,
label or placard identifying the test vehicle year, make and model, NHTSA number
and date shall appear in each photograph and shall be legible. Each still
photograph shall be labeled as to the subject matter.
As a minimum the following pretest and post test still photographs shall be
included in each vehicle final test report, submitted by the contractor:
A. Front view of vehicle
B. Left side view of vehicle
C. Right side view of vehicle
D. Rear view of vehicle
E. 3/4 frontal view from left side of vehicle
F. 3/4 rear view from right side of vehicle
G. Underbody view of fuel tank area and fuel system components
H. Underbody view of engine area and fuel system components
I. Vehicle's certification label (pretest only)
J. Vehicle's tire information label (pretest only)
K. Full view of windshield with and without zone template (frontal test only)
L. Other photographs requested by COTR

TP-301-03 Page 11
9.2 CAMERA COVERAGE
High-speed photographic coverage:
The contractor shall document the crash event by a combination of high-speed color digital
cameras and/or high-speed color 16 mm motion picture cameras or, if possible, all high-speed
digital cameras. The specification for "high-speed digital cameras" and “high-speed motion
picture cameras” are listed below.
Film and digital files shall be on a compact disc as AVI or MPEG files with standard or genrally
available “codec.” Other types of files can be used if approved by the COTR. The film shall be
scanned in at a resolution of 1920 x 1035 pixels. Other scanned film resolutions can be used if
approved by the COTR.
Specifications:
1. High-speed motion picture cameras shall record on 16 mm color negative film and
operate at 1000 frames per second for at least 10 ms before barrier contact and for at
least 310 ms after barrier contact.
A timing mark must be registered on the film edge a minimum of every 10 ms and a
time zero impact mark must be registered on the film to indicate when contact with the
barrier is made in the crash test. The contractor shall report all camera locations along
with camera speeds and lens focal lengths on the appropriate final report data sheets.
Camera locations will be referenced to the barrier face and monorail centerline with the
X, Y, and Z coordinates of the film recorded for each camera.
2. High-speed digital cameras shall record at 1000 frames per second for at least 10 ms
before barrier contact and for at least 310 ms after barrier. The minimum resolution for
these cameras shall be 1536 CMOS sensors per every two rows of pixels, with 80% of
the horizontal distance of the two rows covered by effective light sensors. There shall
be a minimum of 1024 rows of sensors. Some cameras views may not need to meet
these specifications. Cameras that do not meet these specifications may be used if
approved by the COTR. Digital files shall be on a compact disc saved as an AVI or
MPEG file with standard or generally available "codec." Other types of files can be
used if approved by the COTR
A time zero light must be registered in a frame to indicate when contact with the barrier
is made in a crash test or when the air bag is fired in a low risk deployment test in order
to permit vehicle and dummy kinematics analysis on a film analyzer. The contractor
shall report all camera locations along with camera speeds and lens focal lengths on the
appropriate final repot data sheets. Camera locations will be referenced to the barrier
face and monorail centerline with the X, Y, and Z coordinates of the film recorded for
each camera.
When a combination of film and digital cameras is used, the COTR will advise the contractor as to
where the digital cameras will be utilized.
TP-301-03 Page 12
Real time photographic coverage
The contractor shall use a "real time" color digital and/or color motion picture camera with
at least 24 fps to record the installation of the fuel filler cap onto the filler neck and the
rotation of the cap to the installed position. The installation of the filler cap shall appear in
the final version of the 16 mm motion picture or as a single motion picture file. The
contractor shall also use this camera to record the right side of the vehicle or moving
barrier as it travels down the tow road and through the impact event. The contractor shall
use a hand held "real time" color digital or color camera with at least 24 fps to record any
fluid spillage and its collection after the impact or during static rollover.
9.3 CAMERA LOCATIONS
A. Frontal Impact Test
REAL TIME CAMERA 3
4
CONCRETE
BARRIER
MONORAIL
5 TEST
VEHICLE
TOW ROAD
2
CONCRETE PAD
1
TOP VIEW
TP-301-03 Page 13
9. PHOTOGRAPHIC DOCUMENTATION....continued
5
CONCRETE
BARRIER
MONORAIL
Plexiglas
6 PHOTO PIT 7
LEFT SIDE VIEW
CAMERA 1 A high-speed motion picture camera placed in an area to

capture the left-side of the test vehicle during the impact
event. The centerline of the camera shall be perpendicular to
the longitudinal centerline of the vehicle.

capture a close-up, three-quarter’s front and left side view of
the test vehicle.
CAMERA 3 A real time motion picture camera placed in an area to

capture a right-side pan view of the impact event.

capture a a close-up, three-quarter’s front and right side view
of the vehicle.
CAMERA 5 A high speed motion picture camera placed along the

longitudinal centerline of the test vehicle to capture the front
view of the test vehicle during impact.
TP-301-03 Page 14
CAMERA 6 A high-speed motion picture camera positioned in the

photographic pit beneath the front half of the vehicle's
underbody to document any Stoddard solvent spillage.

photographic pit beneath the rear half of the vehicle's
B. Rear Impact Tests
This test describes the 30 mph rear impact test. The new 50 mph rear impact test is currently
being phased-in (complete phase-in by September 1, 2008). See TP-301R for the 50 mph rear
impact test.
REAL TIME CAMERA 2 4
NO STEEL GRATING ALLOWED OVER PHOTO PIT
TEST
VEHICLE
3
CONCRETE PAD TOW ROAD
TOP VIEW
TP-301-03 Page 15
MOVING BARRIER
PHOTO PIT
7 6 5
LEFT SIDE VIEW

capture the left rear-side of the test vehicle during the impact
CAMERA 2 A real time motion picture camera placed in an area to

capture a right-side pan view of the impact event.
CAMERA 3 A high-speed motion picture camera placed on the moving

barrier along its longitudinal centerline to capture a close-up
view of the impact event.

capture the right rear-side of the test vehicle during the impact

photographic pit beneath the rear half of the vehicle's
TP-301-03 Page 16

photographic pit beneath the middle of the vehicle's

photographic pit beneath the front of the vehicle's underbody
to document any Stoddard solvent spillage.
CAMERA 8 A high-speed motion picture camera suspended above the

impact area to capture the entire impact event (not shown in
Figure)
C. Lateral Impact Tests
The Lateral Impact Test is identical to the FMVSS No. 214 Test Procedure. See
this test procedure for conducting this impact test.
D. UNDERBODY PAINT
The underbody of the test vehicle shall be painted flat white and the various
fuel system components such as the fuel tank, filler pipe, supply line, return
line, etc., painted in contrasting colors such as red, green, orange, etc., to
aid photography and identification placards used as previously noted.
10. DEFINITIONS
DAYLIGHT OPENING (DLO)
Maximum unobstructed opening through the glazing surface (windshield), including

reveal or garnish moldings adjoining the surface, as measured parallel to the outer
surface of the glazing material.
DESIGNATED SEATING CAPACITY (DSC)
Number of designated seating positions (DSPs) provided.
DESIGNATED SEATING POSITION (DSP)
Any plan view location capable of accommodating a person at least as large as a

5th- percentile adult female, if the overall seat configuration and design and
vehicle design is such that the position is likely to be used as a seating position
while the vehicle is in motion, except for auxiliary seating accommodations such
as temporary or folding jump seats. Any bench or split-bench seat in a passenger
car, truck or multipurpose passenger vehicle (MPV) with a GVWR less than 4,536
kg, having greater than 1270 mm of hip room (measured in accordance with SAE
J1100a) shall have not less than 3 designated seating positions, unless the seat
TP-301-03 Page 17
10. DEFINITIONS....continued
design or vehicle design is such that the center position cannot be used for
seating.
FIXED COLLISION BARRIER

(used for perpendicular Frontal and 1° to 30° Oblique impacts)
A flat, vertical, unyielding surface with the following characteristics:
A. At a minimum, the barrier shall consist of a reinforced concrete structure 1.8

meters high, 1.8 meters thick and 3.6 meters wide, weighing at least 45,360
kg. The barrier face shall be adjustable for conducting 30° oblique impact
tests. The barrier face shall be faced with a sheet of 19 mm inch thick
exterior plywood which is 1.2 meters high by 2.4 meter wide. The plywood
shall be replaced as necessary during the compliance testing program.
B. The surface is sufficiently large that when struck by a test vehicle, no

portion of the vehicle projects or passes beyond the surface.
C. When struck by a vehicle, the surface and its supporting structure absorb
no significant portion of the vehicle's kinetic energy.
FORWARD CONTROL VEHICLE (FCV)
Configuration in which more than half of the engine length is rearward of the
foremost point of the windshield base and the steering wheel hub is in the forward
quarter of the vehicle length.
FUEL SPILLAGE
The fall, flow, or run of fuel from the vehicle but does not include wetness resulting
from capillary action.
GROSS AXLE WEIGHT RATING (GAWR)
Value specified by the vehicle manufacturer as the load-carrying capacity of a

single axle system, as measured at the tire-ground interfaces.
GROSS VEHICLE WEIGHT RATING (GVWR)
Value specified by the manufacturer as the loaded weight of a single vehicle.
LONGITUDINAL OR LONGITUDINALLY
Parallel to the longitudinal centerline of the vehicle.

TP-301-03 Page 18
MULTIPURPOSE PASSENGER VEHICLE (MPV)
Motor vehicle with motive power, except a trailer, designed to carry 10 persons or
less which is constructed either on a truck chassis or with special features for
occasional off- road operation.
UNLOADED VEHICLE WEIGHT (UVW)
Weight of a vehicle with maximum capacity of all fluids necessary for operation of
the vehicle, but without cargo, occupants, or accessories that are ordinarily
removed from the vehicle when they are not is use.
VEHICLE FUEL TANK ASSEMBLY
FILLER PIPE VOLUME
VAPOR VOLUME
FUEL LINE
FILLER CAP
USABLE
CAPACITY
UNUSABLE CAPACITY
VEHICLE FUEL TANK CAPACITY
Fuel tank's unusable capacity (i.e., the volume of fuel left at the bottom of the tank
when the vehicle's fuel pump can no longer draw fuel from the tank) plus its usable
capacity (i.e., the volume of fuel that can be pumped into the tank through the filler
pipe with the vehicle on a level surface and with the unusable capacity already in
TP-301-03 Page 19
the tank). The term does not include the vapor volume of the tank (i.e., the space
above the fuel tank filler neck) nor the volume of the fuel tank filler neck.
NOTE: The "usable capacity" and "unusable capacity" figures will be furnished by
the COTR. This information is obtained from the vehicle manufacturers.
11. PRETEST REQUIREMENTS
Prior to conducting any compliance tests, contractors shall submit a detailed in-house
compliance test procedure to the COTR, which includes a step-by-step description of the
methodology to be used. The contractor shall obtain written approval from the COTR
before initiating the compliance test program so that all parties are in agreement.
The contractor's test procedure shall contain a complete listing of test equipment and a
detailed check-off list. There shall be no contradiction between the OVSC Laboratory
Test Procedure (TP) and the contractor's in-house test procedure. The list of test
equipment shall include instrument accuracy and calibration dates.
TEST DATA LOSS
A compliance test shall not to be conducted unless all of the various test conditions
specified in the applicable OVSC Laboratory Test Procedure are met. Failure of a
contractor to obtain the required test data and to maintain acceptable limits on test
parameters (such as impact velocity) in the manner outlined in the applicable OVSC
Laboratory Test Procedure shall require a retest at the expense of the contractor. The
retest costs shall include the cost of the replacement vehicle or item of motor vehicle
equipment and the service costs for conducting the retest.
PHOTOGRAPHIC PITS
Photographic pits shall be located in the tow road both at the fixed collision barrier face
and at mid-range so that any possible Stoddard solvent spillage can be photographed
during a frontal, oblique, rear or lateral impact event. Pit obstructions such as cross
supports, excessive grating (applies to frontal and oblique impacts only), monorail, etc.
shall be removed from the field of view of the 2 or 3 pit high speed motion picture
cameras.
TEST VEHICLE AND MOVING BARRIER GUIDANCE
A guidance system is required to assure that the test vehicle or the moving barrier
impacts the target at the proper angle. Normally the monorail, which extends along the
center of the tow road, is used for lateral guidance with a small dolly or guide shoe
"riding" on the monorail and engaging the drive cable through a set of jaws, which grip
the cable. SOLID CONNECTIONS between the guide shoe and the test vehicle or
moving barrier ARE NOT ALLOWED — cables with tensioning turnbuckles extending
from the test vehicle's left and right side lower control arms to the guide shoe shall be
used. The guide shoe is normally released from the monorail at the entrance to the
TP-301-03 Page 20
11. PRETEST REQUIREMENTS.....continued
photographic pit and the test vehicle or moving barrier free wheels into the barrier face or
target vehicle. The monorail shall not extend over the photographic pit. The release of
the barrier shall take place between 152 and 610 mm from the impacted side of the test
vehicle. There shall be a minimum amount of steel grating over the fixed collision barrier
photographic pit in order to allow for maximum photographic coverage of the test
vehicle's underbody area.
NOTE: Per the requirements of FMVSS 301, steel grating is NOT allowed for rear impact
tests. The test vehicle shall be placed on a concrete test surface.
12. TEST EXECUTION
12.1 TEST VEHICLE PREPARATION
A. VEHICLE TEST WEIGHT AS DELIVERED (UVW)
After the test vehicle is received, add fluids to levels specified in the owner’s
manual and then weigh the vehicle. Record on data sheet as "Unloaded
Vehicle Weight" (UVW).
TARGET TEST WEIGHT (TTW)
Calculate the vehicle’s Rated Cargo and Luggage Weight (RCLW). RCLW
is determined by using the information contained on the vehicle’s tire
placard required by FMVSS 110, “Tire Selection and Rims,” and usually
affixed to the vehicle’s left B post. Standard 110 requires that the Vehicle
Capacity Weight (VCW) and Designated Seating Capacity (DSC) or number
of occupants be recorded on the tire placard. Calculate and record RCLW
as follows:
RCLW = VCW - (DSC X 68 kg. per occupant)
If Standard 110 information is not available for a MPV, light truck or bus,
use the following calculation:
RCLW = GVWR - UVW - (68 kg x DSC), where DSC is obtained by

counting the total number of seat belt locations throughout the
vehicle
Calculate and record the Target Test Weight (TTW) as follows:
TTW = UVW + RCLW + (2 dummies x 74 kg. /dummy)
MPV’s, light trucks and buses with a MAXIMUM GVWR 4,536 kg are
loaded to UVW , plus 136 kg or its RCLW (furnished by the COTR),
whichever is LESS, secured to the vehicle, plus a Part 572 dummy at each
front outboard seating position.
TP-301-03 Page 21
12. TEST EXECUTION......continued
AS TESTED (ACTUAL TEST WEIGHT)
Drain the fuel system and operate the engine until the fuel system is dry.
Slowly refill the entire fuel system (rotate engine) with Stoddard solvent
which has been dyed purple, having the physical and chemical properties of
Type 1 solvent or cleaning fluid, Table 1, ASTM Standard D484-71,
"Standard Specifications for Hydrocarbon Dry-cleaning Solvents" until, not
less than 92 percent and not more than 94 percent, of the vehicle
manufacturer's stated "usable capacity" is reached (use the useable
capacity supplied by manufacturer, do not use values in the owners
manual). This volume will be furnished by the COTR.
Stoddard solvent shall be filtered while being introduced into the fuel
system. Drain all other fluids from the test vehicle with the exception of
brake fluid if required for abort system, so that Stoddard solvent leakage
from the fuel system shall be evident. Just prior to the test, operate the
engine to assure that Stoddard solvent is present throughout the entire fuel
system.
Load the vehicle with the required test dummies and necessary on-board
test equipment (including all instrumentation, cameras, lighting, etc.) and
then add ballast, if necessary, to achieve the Target Test Weight. The load
is distributed so that the weight on each axle as measured at the tire-
ground interfaces is in proportion to its GAWR.
The Actual Test Weight (ATW) shall have the following boundaries;
(TTW - 9 kg.) ≤ ATW ≤ TTW
If the ATW exceeds TTW, the contractor shall notify the COTR to discuss
the possible removal of vehicle components or instrumentation, which
would decrease the weight.
UNDER NO CIRCUMSTANCES SHALL THE ACTUAL TEST WEIGHT

(ATW) BE GREATER THAN THE TARGET TEST WEIGHT (TTW).
B. VEHICLE ATTITUDE MEASUREMENTS
If the test vehicle has an AUTO-LEVELING SYSTEM the system shall be

powered (ignition "on") when attitude measurements are made.
TP-301-03 Page 22
AS DELIVERED ATTITUDE
With the test vehicle in the “As Delivered” (full fluids) condition, position the
vehicle on a level surface and inflate all tires to the manufacturer's
specifications as listed on the vehicle's tire information label or placard.
Measure the distance between each of the four tire-to-ground interfaces
and a pre-selected reference point on the test vehicle’s body, directly above
each wheel opening. Record on data sheet as the “As Delivered” attitude.
AS TESTED ATTITUDE
With the test vehicle in the “As Tested” condition, position the vehicle on a
level surface and inflate all tires to the manufacturer's specifications as
listed on the vehicle's tire information label or placard. Measure the
distance between each of the four tire-ground interfaces and the pre-
selected reference point (same points used for “As Delivered”) on the test
vehicle’s body directly above each wheel opening. Record on data sheet
as the “As Tested” attitude.
C. FRONT SEAT CUSHION ADJUSTMENT
Adjustable front seats are in the adjustment position MIDWAY between the
forwardmost and rearmost positions, and if separately adjustable in a
vertical direction, are at the LOWEST position. If an adjustment position
does not exist midway between the forwardmost and rearmost positions,
the closest adjustment position to the REAR of the midpoint is used.
Record the extremes of seat cushion adjuster fore and aft travel and the
midpoint on the vehicle's rocker panel or side sill cover plate using a black
marker after placing a vertical reference line on the outboard side of the
front seat(s).
D. FRONT SEAT BACK ADJUSTMENT
Place adjustable front seat backs in the vehicle manufacturer's NOMINAL

DESIGN RIDING POSITION in the manner specified by the manufacturer
(information to be furnished by COTR). Place each adjustable head
restraint in its highest adjustment position. Adjustable lumbar supports are
positioned so that the lumbar support is in its LOWEST adjustment position.
E. STEERING COLUMN ADJUSTMENT
Adjustable steering controls are adjusted so that the steering wheel hub is
at the geometric center of the locus it describes when it is moved through
its full range of driving positions. If there is no center position, use the next
upper or lower position as supplied by the manufacturer.
TP-301-03 Page 23
F. PART 572B OR 572E TEST DUMMIES
50th-percentile adult male Part 572 test dummies are placed in each front
outboard seating position. The following instructions apply:
(1). In vehicles equipped with bench seats, the upper torso of driver and
passenger test dummies shall rest against the seat back. The
midsagittal plane of the driver dummy shall be vertical and parallel to
the vehicle’s longitudinal centerline, and pass through the center of
the steering wheel rim. The midsagittal plane of the passenger
dummy shall be vertical and parallel to the vehicle’s longitudinal
centerline and the same distance from the vehicle’s longitudinal
centerline as the midsagittal plane of the driver dummy.
(2). In vehicles equipped with bucket seats, the upper torso of the driver
and passenger test dummies shall rest against the seat back. The
midsagittal plane of the driver and passenger dummy shall be
vertical and shall coincide with the longitudinal centerline of the
bucket seat.
(3). Dummies are restrained only by means that are installed in the test
vehicle. Consult vehicle's owners manual for proper usage of
occupant restraints.
G. SECURING BALLAST
Double canvas bags filled with sand, or lead shot shall be secured in the
luggage or cargo area (at the centroid of luggage mass if possible) using
seat belt webbing or steel straps attached to the vehicles rear floorpan.
Steel plates may be secured to the cargo area as long as securement
devices are not in the vicinity of any fuel system component.
H. MOVABLE WINDOW PLACEMENT
Movable vehicle windows and vents are placed in the fully open position.
I. CONVERTIBLE TOP PLACEMENT
Convertibles and open-body type vehicles have the top, if any, in place in
the closed passenger compartment configuration.
J. DOOR LATCH PLACEMENT
Doors are fully closed and latched but not locked.

TP-301-03 Page 24
K. PARKING BRAKE AND TRANSMISSION PLACEMENT
The parking brake is disengaged and the transmission is in neutral.
TEST REQUIREMENTS FOR FMVSS 212, WINDSHIELD MOUNTING
When a passenger car, multipurpose passenger vehicle (MPV), light truck or bus (GVWR
of 4,536 Kg or less and MAXIMUM unloaded vehicle weight or UVW of 2,495 Kg)
traveling longitudinally forward at 47.3 km/h ± 0.8 km/h impacts a fixed collision barrier
that is perpendicular to the line of travel of the vehicle (PERPENDICULAR FRONTAL
IMPACT TEST), the windshield mounting of the vehicle shall retain NOT LESS than the
minimum portion of the windshield periphery as follows:
A. Vehicles equipped with automatic occupant restraint systems shall retain not less
than 50% of the portion of the windshield periphery on each side of the vehicle
longitudinal centerline.
B. Vehicles NOT equipped with automatic occupant restraint systems shall retain not
less than 75% of the windshield periphery.
NOTE: The standard does NOT apply to vehicles with a UVW greater than 2,495 Kg or
to forward control vehicles, walk-in van-type vehicles, or to open-body-type vehicles with
fold-down or removable windshields.
The following test condition shall apply: The windshield mounting material and all vehicle
components in direct contact with the mounting material are at any temperature between
–9.4 ºC and 43.3 ºC. Temperature measurement shall be made 15 minutes before the
frontal impact test.
TEST REQUIREMENTS FOR FMVSS 219, WINDSHIELD ZONE INTRUSION

- Compliance Test
When a passenger car, multipurpose passenger vehicle (MPV), light truck or bus (GVWR
of 4,536 kg or less) traveling longitudinally forward at 47.3 km/h plus or minus 0.8 km/h
impacts a fixed collision barrier that is perpendicular to the line of travel of the
TP-301-03 Page 25
vehicle (PERPENDICULAR FRONTAL IMPACT TEST), no part of the vehicle outside the
occupant compartment, except windshield molding and other components designed to be
normally in contact with the windshield, shall penetrate the protected zone template,
affixed to the windshield, to a depth of more than 6.4 mm, and no such part of the vehicle
shall penetrate the inner surface of that portion of the windshield, within the daylight
opening (DLO) below the protected zone.
NOTE: The standard does NOT apply to forward control vehicles, walk-in van-type
vehicles, or to open-body-type vehicles with fold-down or removable windshields.
Protected Zone Template — The lower edge of the protected zone is determined by the
following:
A. Place a 16.5 cm diameter rigid sphere weighing 6.8 kg in a position such that it
simultaneously contacts the inner surface of the windshield glazing and the
surface of the instrument panel, including padding. If any accessories or
equipment such as the steering control system obstruct positioning of the sphere,
remove them, and then replace them prior to barrier impact testing.
B. Draw the locus of points on the inner surface of the windshield contactable by the
sphere across the width of the instrument panel. From the outermost contactable
points, extend the locus line horizontally to the edges of the glazing material.
NOTE: Do not scratch glazing as a method of marking the contact between sphere
and windshield.
C. Draw a line on the inner surface of the windshield below and 1.3 cm distant from
the locus line.
D. The lower edge of the protected zone is the longitudinal projection onto the outer
surface of the windshield on the line determined in item C.
The Protected Zone is the space enclosed by the following surfaces:
A. The outer surface of windshield in the pre-crash configuration.
B. The locus of points 7.6 cm outward along perpendiculars drawn to each point on
the outer surface of the windshield.
C. The locus of lines forming a 45º angle with the outer surface of the windshield at
each point along the top and side edges of the outer surface of the windshield and
the lower edge of the protected zone previously determined, in the plane
perpendicular to the edge at that point.
A Windshield Zone Template (WZT) is cut or formed from Styrofoam, type DB, cut cell, to
the dimensions of the protected zone previously determined. The WZT is affixed to the
windshield so that it delineates the protected zone and remains affixed throughout the
frontal barrier impact compliance test. The following test conditions shall apply:
TP-301-03 Page 26
A. The protected zone template is affixed to the windshield in a manner previously

described.
B. The hood, hood latches, and any other hood retention components are engaged
prior to the frontal barrier impact test.
C. Adjustable cowl tops or other adjustable panels in front of the windshield are in the
position used under normal operating conditions when windshield-wiping systems
are not in use.
FRONT VIEW OF WINDSHIELD
Y
E F B
D X
LOWER EDGE OF PROTECTED ZONE
ZERO POINT (0,0)

TP-301-03 Page 27
12. TEST EXECUTION....Continued
CROSS-SECTIONAL VIEW OF PROTECTED ZONE TEMPLATE

45° ANGLE
ROOF PANEL
STYROFOAM TEMPLATE
WINDSHIELD
7.6 cm
LEFT SIDE VIEW
45° ANGLE
COWL PANEL
NOTE: VERTICAL SLOTS CUT IN FOAM TEMPLATE

ON SIDE WHICH IS PLACED AGAINST WINDSHIELD
TEST REQUIREMENTS FOR FMVSS 219, WINDSHIELD ZONE INTRUSION

- INDICANT TEST
To perform the FMVSS 219 Indicant Test, determine the Protective Zone as
described above in the FMVSS Compliance Test Procedure. Draw a line defining the
Protective Zone but do not use a Styrofoam Windshield Template. Penetration to
the windshield shall be determined solely by any visible intrusion on the windshield
after the Perpendicular Frontal Impact Test and review of the high-speed film.
TP-301-03 Page 28
12.2 FIXED BARRIER CRASH TEST
A. Impact Speed
The test vehicle is towed longitudinally forward at a speed of 47.3 km/h ± 0.8 km/h
when it impacts a fixed collision barrier.
B. Impact Angle
Full Frontal - The line of travel is perpendicular (90°, +/- 5°) to the fixed collision
barrier.
Oblique Angle - The line of travel is at any angle (5° to 25° +/- 5°) in either
direction from the perpendicular (90°,+/- 5°) of the fixed collision barrier.
CO NC RETE
BARR IER
TE ST
VE HIC LE
G RATIN G
MO NO RAIL
PHO TO PIT
TOP VIEW
TP-301-03 Page 29
12. TEST EXECUTION.....continued
12.3 REAR MOVING BARRIER CRASH
The following test describes the 30 mph rear impact test. The new 50 mph
rear impact test is currently being phased-in (complete phase-in by
September 1, 2008). See TP-301R for the 50 mph rear impact test.
The test vehicle is positioned on the level, concrete test pad area as illustrated in
the diagram. The test vehicle is aligned on the track to assure the moving barrier
impacts at the angle as described below. Also, the test vehicle is placed in a
position to assure that the cameras in the photo pit capture the entire impact event
from the moment the moving barrier makes initial contact with the test vehicle until
separation of the moving barrier and test vehicle.
A. Impact Speed
The moving barrier is guided so that it travels in a straight line, with no significant
lateral, vertical or rotational movement. The moving barrier impacts the rear of the
stationary test vehicle at a speed of 47.3 km/h ± 0.8 km/h
B. Impact Angle
The moving barrier impacts the stationary test vehicle such that a vertical plane
through the geometric center of the barrier impact surface and perpendicular,
(90°+/- 5°) to that surface coincides with the longitudinal centerline of the test
vehicle.
TP-301-03 Page 30
12. TEST EXECUTION.....continued PHOTO PIT MONORAIL
12.4 LATERAL MOVING BARRIER CRASH

TEST
The Lateral Impact Test is identical to the VEHICLE
FMVSS No. 214 Test Procedure. See this test
procedure for conducting this impact test.
12.5 COLLECTION OF STODDARD SPILLAGE
Collect Stoddard solvent spillage, if any,

immediately after impact using the most
efficient method available. Weigh the total
amount of spillage. Stoddard solvent spillage,
from the moment the vehicle ceases motion,
shall not exceed a total of 142 g by weight for
5 minutes after the vehicle comes to rest.
12.6 STATIC ROLLOVER

MOVING
BARRIER
Within 30 minutes after the impact test, the test
vehicle is rotated on the Static Rollover Device TOP
to each successive increment of 90° through VIEW
360° at a uniform rate, with a full 90° of rotation
taking place in any time interval from 1 to 3
minutes. After reaching each 90° increment the vehicle is held in that position for 5
minutes.
NOTE: If there is an indication of a test failure during or just after the impact test, DO
NOT conduct the static rollover test.
(1) Remove test dummies and de-power systems.
(2) Carefully secure the test vehicle on the Static Rollover Device so as not to
cause any damage to fuel system components or fuel lines.
(3) Begin rotating the vehicle for the first 90° increment. Record time rotation
begins and ends. The vehicle shall be held in this position for 5 minutes after
rotation ends.
(4) Collect Stoddard solvent spillage, if any, from the onset of rotation or the time
rotation began up to 5 minutes thereafter.
Note: If there is an indication of a test failure during any 90° increment of the rollover test,
STOP THE TEST. Do not continue to the next successive 90° increment.
(5) Change collection containers. Record any spillage that occurs during the 6th
minute after the onset of rotation or when rotation began.
TP-301-03 Page 31
(6) If required, change collection containers. Record any spillage that occurs
during the 7th minute after the onset of rotation or when rotation began.
(7) If required, change collection containers. Record any spillage that occurs
during the 8th minute after the onset of rotation or when rotation began.
Repeat for 90° to 180°, 180° to 270° and 270° to 360° increments.
PASS OR FAIL CRITERIA - Stoddard solvent spillage, from the onset of rotational
motion, shall not exceed a total of 142 grams for the first 5 minutes of testing at
each successive 90° increment. For the remaining testing period, at each
increment of 90°, solvent spillage during any 1-minute interval shall not exceed 28
grams.
13. TEST DATA DISPOSITION
The contractor shall make all vehicle preliminary compliance test data available to
the COTR at the test site within twenty-four hours after the test. Final test data,
including digital printouts and computer generated plots (if applicable), shall be
furnished to the COTR within 5 working days. Additionally, the contractor shall
analyze the preliminary test results as directed by the COTR.
All backup data sheets, strip charts, recordings, plots, technician's notes, etc.,
shall be either sent to the COTR or destroyed at the conclusion of each delivery
order, purchase order, etc...
TEST DATA LOSS
A compliance test is not to be conducted unless all of the various test conditions
specified in the applicable OVSC Laboratory Test Procedure are met. Failure of a
contractor to obtain the required test data and to maintain acceptable limits on test
parameters (such as impact velocity) in the manner outlined in the applicable
OVSC Laboratory Test Procedure shall require a retest at the expense of the
contractor. The retest costs shall include the cost of the replacement vehicle or
item of motor vehicle equipment and the service costs for conducting the retest.
The original GFP will become the property of the contractor after the retest has
been successfully conducted.
14. REPORTS
14.1 MONTHLY STATUS REPORTS
The contractor shall submit a monthly Test Status Report and a Vehicle Status
Report to the COTR. The Vehicle Status Report shall be submitted until all
vehicles are disposed. Samples of the required Monthly Status Reports are
contained in the report forms section.
TP-301-03 Page 32
14. REPORTS.....continued
14.2 APPARENT NONCOMPLIANCE
A test failure shall be communicated by the contractor to the COTR within 24

hours with written notification mailed within 48 hours (Saturdays and Sundays
excluded). A Notice of Test Failure (see report forms section) with a copy of the
particular compliance test data sheet(s) and preliminary data plot(s) shall be
included. In the event of a test failure, a post test calibration check of some
critically sensitive test equipment and instrumentation may be required for
verification of accuracy. The necessity for the calibration shall be at the COTR's
discretion and shall be performed without additional costs to the OVSC.
14.3 FINAL TEST REPORTS
14.3.1 COPIES
In the case of a test failure, the contractor shall submit SEVEN hard copies and
one PDF formatted copy of the Final Test Report to the COTR for acceptance
within three weeks of test completion. The Final Test Report format to be used by
all contractors can be found in the Report Section.
Where there has been no indication of a test failure, the contractor shall submit
FOUR hard copies and one PDF formatted copy of each Final Test Report to the
COTR within three weeks of test completion. Payment of contractor's invoices for
completed compliance tests may be withheld until the Final Test Report is
accepted by the COTR. Contractors are requested to NOT submit invoices before
the COTR is provided copies of the Final Test Report.
Contractors shall submit the first Final Test Report in draft form within two weeks
after the compliance test is conducted. The contractor and the COTR will then be
able to discuss the details of both test conduct and report content early in the
compliance test program.
Contractors shall PROOF READ all Final Test Reports before submittal to the
COTR. The OVSC will not act as a report quality control office for contractors.
Reports containing a significant number of errors will be returned to the contractor
for correction, and a "hold" will be placed on invoice payment for the particular
test.
14.3.2 REQUIREMENTS
The Final Test Report, associated documentation (including photographs) are

relied upon as the chronicle of the compliance test. The Final Test Report will be
released to the public domain after review and acceptance by the COTR. For
these reasons, each final report shall be a complete document capable of standing
by itself. The contractor shall use detailed descriptions of all compliance test
events. Any events that are not directly associated with the standard but are of
technical interest shall also be included. The contractor shall include as much
TP-301-03 Page 33
detail as possible in the report. Instructions for the preparation of the first three
pages of the final test report are provided below for the purpose of standardization.
14.3.3 FIRST THREE PAGES
A. FRONT COVER —
A heavy paperback cover (or transparency) shall be provided for the

protection of the final report. The information required on the cover is as
follows:
(1) Final Report Number such as 301-ABC-9X-001 where

301 is the FMVSS tested
ABC are the initials for the laboratory
0X is the Fiscal Year of the test program
001 is the Group Number (001 for the 1st test,
002 for the 2nd test, etc.)
(2) Final Report Title And Subtitle such as
SAFETY COMPLIANCE TESTING FOR FMVSS 301

Fuel System Integrity
****************
World Motors Corporation
2000 XYZ 4-door sedan
NHTSA No. CX0401
(3) Contractor's Name and Address such as
COMPLIANCE TESTING LABORATORIES, INC.

4335 West Dearborn Street
Detroit, Michigan 48090
NOTE: DOT SYMBOL WILL BE PLACED BETWEEN ITEMS (3) AND (4)
(4) Date of Final Report completion
(5) The words "FINAL REPORT"
(6) The sponsoring agency's name and address as follows
U. S. DEPARTMENT OF TRANSPORTATION
National Highway Traffic Safety Administration
Enforcement
Office of Vehicle Safety Compliance
Room 6111 (NVS-220)
TP-301-03 Page 34
B. FIRST PAGE AFTER FRONT COVER —
A disclaimer statement and an acceptance signature block for the COTR

shall be provided as follows;
This publication is distributed by the U. S. Department of

Transportation, National Highway Traffic Safety
Administration, in the interest of information exchange. The
opinions, findings and conclusions expressed in this
publication are those of the author(s) and not necessarily
those of the Department of Transportation or the National
Highway Traffic Safety Administration. The United States
Government assumes no liability for its contents or use
thereof. If trade or manufacturers' names or products are
mentioned, it is only because they are considered essential to
the object of the publication and should not be construed as
an endorsement. The United States Government does not
endorse products or manufacturers.
Prepared By:
Approved By:
Approval Date:
FINAL REPORT ACCEPTANCE BY OVSC:
Accepted By:
Acceptance Date:
TP-301-03 Page 35
C. SECOND PAGE AFTER FRONT COVER —
A completed Technical Report Documentation Page (Form DOT F1700.7)

shall be completed for those items that are applicable with the other spaces
left blank. Sample data for the applicable block numbers of the title page
follows.
Block 1 — REPORT NUMBER
301-ABC-9X-001
Block 2 — GOVERNMENT ACCESSION NUMBER
Leave blank
Block 3 — RECIPIENT'S CATALOG NUMBER
Leave blank
Block 4 — TITLE AND SUBTITLE
Final Report of FMVSS 301 Compliance Testing of 2000 World XYZ

4- door sedan, NHTSA No. CY000
Block 5 — REPORT DATE
March 1, 2000
Block 6 — PERFORMING ORGANIZATION CODE
ABC
Block 7 — AUTHOR(S)
John Smith, Project Manager / Bill Doe, Project Engineer
Block 8 — PERFORMING ORGANIZATION REPORT NUMBER
ABC-DOT-XXX-001
Block 9 — PERFORMING ORGANIZATION NAME AND ADDRESS
ABC Laboratories
405 Main Street
Detroit, MI 48070
TP-301-03 Page 36
Block 10 — WORK UNIT NUMBER
Leave blank
Block 11 — CONTRACT OR GRANT NUMBER
DTNH22-9X-D-12345
Block 12 — SPONSORING AGENCY NAME AND ADDRESS
US Department of Transportation
National Highway Traffic Safety Administration
Enforcement
Office of Vehicle Safety Compliance (NVS-220)
400 Seventh Street, SW, Room 6111
Block 13 — TYPE OF REPORT AND PERIOD COVERED
Final Test Report

Feb. 15 to Mar. 15, 2000
Block 14 — SPONSORING AGENCY CODE
NVS-220
Block 15 — SUPPLEMENTARY NOTES
Leave blank
Block 16 — ABSTRACT
Compliance tests were conducted on the subject 2000 World XYZ 4-

door sedan in accordance with the specifications of the Office of
Vehicle Safety Compliance Test Procedure No. TP-301-0X to assure
FMVSS 301 compliance. Test failures identified were as follows:
None
NOTE: Above wording shall be shown with appropriate changes

made for a particular compliance test. Any questions should be
resolved with the COTR.
TP-301-03 Page 37
Block 17 — KEY WORDS
Compliance Testing
Safety Engineering
FMVSS 301
Block 18 — DISTRIBUTION STATEMENT
Copies of this report are available from —

NHTSA Technical Information Services
Room 5111 (NPO-230)
400 Seventh St., SW
Telephone No.: 202-366-2588
Block 19 — SECURITY CLASSIFICATION OF REPORT
Unclassified
Block 20 — SECURITY CLASSIFICATION OF PAGE
Unclassified
Block 21 — NUMBER OF PAGES
Add appropriate number
Block 22 — PRICE
Leave blank
14.3.4 TABLE OF CONTENTS
Final test report Table of Contents shall include the following:
Section 1 — Purpose of Compliance Test
Section 2 — Compliance Test Results Summary
Section 3 — Compliance Test Data
Appendix A — Photographs
TP-301-03 Page 38
SECTION 1 - PURPOSE OF COMPLIANCE TEST
This section briefly outlines the purpose for conducting the compliance test and states the
appropriate OVSC test procedure followed during the test. The following is provided as
an example;
Section 1
Purpose of Compliance Test
This 30 mph rear moving barrier impact test is a part of the Federal Motor Vehicle
Safety Standard (FMVSS) 301 Compliance Test Program conducted for the National
Highway Traffic Safety Administration (NHTSA) by ABC Laboratories under Contract No.
123-456-789. The purpose of this test was to determine if the subject vehicle, a 200X
World XYZ 4-door sedan, meets the performance requirements of FMVSS No. 301, “Fuel
System Integrity.” The test was conducted in accordance with the Office of Vehicle
Safety Compliance Laboratory Test Procedure TP-301-03, dated September 30, 2002.
Note: The description shall be double-spaced on an entire separate page.
SECTION 2 - COMPLIANCE TEST RESULTS SUMMARY
This section gives a summary of the impact event. The following is provided as an
example.
Section 2
Compliance Test Results Summary
A 1500 kg 2000 World XYZ 4-door sedan was impacted from the rear by a 1800
kg moving barrier at a velocity of 47.2 km/h. The test was performed by ABC
Laboratories in Detroit, Michigan, on November 15, 200X.
The test vehicle was equipped with a 70 liter fuel tank which was filled to 93
percent capacity with stoddard fluid prior to impact. Part 572 B non-instrumented, 50th
percentile male Anthropomorphic Test Devices (ATD’s) were place in the driver and right-
front outboard designated seating positions respectively.
There was no fuel system fluid spillage following the impact event or during any
portion of the static rollover test. The average longitudinal crush was 300 millimeters.
The vehicle appeared to comply with all the requirements of FMVSS No. 301 “Fuel
System Integrity.”
The crash event was recorded by one real time camera and eight high-speed
cameras. Pre- and post-test photographs of the test vehicle can be found in Appendix A.
Note: The summary shall be double-spaced on an entire separate page.

TP-301-03 Page 39
SECTION 3 - Compliance Test Data
This section contains all of the data recorded and collected during the test. At a
minimum, this section shall include all of the information found in the following Data
Sheets;
Data Sheet No. 1 - Test Vehicle Specifications
Data Sheet No. 2 - Pre-Test Data
Data Sheet No. 3 - Moving Barrier Data (For rear Impacts only)
Data Sheet No. 4 - Post Test Data
Data Sheet No. 5 - Static Rollover Test Data
Data Sheet No. 6 - Summary of FMVSS 212 Data (if applicable)
Data Sheet No. 7 – Summary of FMVSS 219 Data (if applicable)
APPENDIX A - Photographs
At a minimum, the following photographs shall be included in this section
1. Pre-test Front view of vehicle
2. Post-test Front view of vehicle
3. Pre-test Left side view of vehicle
4. Post-test Left side view of vehicle
5. Pre-test Right side view of vehicle
6. Post-test Right side view of vehicle
7. Pre-test Rear view of vehicle
8. Post-test Rear view of vehicle
9. Pre-test 3/4 frontal view from left side of vehicle
10. Post-test 3/4 frontal view left side of vehicle
11. Pre-test 3/4 rear view from right side of vehicle
12. Post-test 3/4 rear view from right side of vehicle

TP-301-03 Page 40
13. Pre-test underbody view of fuel tank area and fuel system components
14. Post-test underbody view of fuel tank area and fuel system components
15. Pre-test underbody view of engine area and fuel system components
16. Post-test underbody view of engine area and fuel system components
17. Vehicle's certification label (pretest only)
18. Vehicle's tire information label (pretest only)

TP-301-03 Page 41
15. DATA SHEETS
Data Sheet No. 1

Test Vehicle Specifications
TEST VEHICLE INFORMATION:
NHTSA No.: ;
Year/Make/Model/Body Style:
Engine Data:
Transmission Data:
Final Drive Data:
Major Options:
Date Received: ; Odometer Reading: miles
DATA FROM VEHICLE'S CERTIFICATION LABEL:
Vehicle Manufactured By:

Date of Manufacture:
VIN:
GVWR: kg. ; GAWR — Front: kg. ; GAWR — Rear: kg.
DATA FROM VEHICLE'S TIRE PLACARD:
Location of Placard on Vehicle:

Tire Pressure With Maximum Capacity Vehicle Load: Front: kPa; Rear: kPa
Recommended Tire Size:
Recommended Load Range:
Recommended Cold Tire Pressure: Front = KPa; Rear = kPa
Size of Tires on Test Vehicle:
Type of Spare Tire:
Vehicle Capacity Data

Type of Front Seat(s):
Number of Occupants: Front = ; Rear = ; Total =
A. VEHICLE CAPACITY WEIGHT (VCW) = kg.
B. Number of Occupants x 68 kg. = kg.
RATED CARGO AND LUGGAGE WEIGHT (RCLW) = (A - B) = kg.
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 42
15. DATA SHEETS....continued
Data Sheet No. 2
Pre-Test Data
WEIGHT OF TEST VEHICLE:
As Delivered At Laboratory (w/ maximum fluids)
Right Front = kg. Right Rear = kg.
Left Front = kg. Left Rear = kg.
TOTAL FRONT = kg. TOTAL REAR = kg.
% of TOTAL = % % of TOTAL = kg.
TOTAL DELIVERED WEIGHT = kg.
Calculation of Target Test Weight (TTW)
1. Total Delivered Weight = kg.
2. Rated Cargo & Lugg. Weight (RCLW) = kg.
3. Weight of 2 Dummies (74 kg. each) = kg.
TARGET TEST WEIGHT = 1 + 2 + 3 = kg.
As Tested
Test Weight of Vehicle, Dummies and kg of Cargo Weight
Right Front = kg. Right Rear = kg.
Left Front = kg. Left Rear = kg.
TOTAL FRONT = kg. TOTAL REAR = kg.
% of TOTAL = % % of TOTAL = %
TOTAL TEST WEIGHT = kg.
Weight of Ballast secured in cargo area = kg.
Type of Ballast:
Method of Securing Ballast:
Vehicle Components Removed for Weight Reduction_______________________
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 43
Data Sheet No. 2

Pre-Test Data
VEHICLE ATTITUDE
As Delivered — Right Front: mm

Left Front: mm
Right Rear: mm
Left Rear: mm
As Tested — Right Front: mm

Left Front: mm
Right Rear: mm
Left Rear: mm
Vehicle's Wheelbase = mm
FUEL SYSTEM DATA:

Fuel System Capacity Listed in Owner's Manual = liters
Usable Capacity Figure Furnished By COTR = liters
Test Volume Range (91 to 94% of Usable Capacity) —
liters TO liters
ACTUAL TEST VOLUME = liters (with entire fuel system filled)

Test Fluid Type: Stoddard solvent
Test Fluid Specific Gravity:
Test Fluid Kinematic Viscosity: centistokes
Test Fluid Color: ("red" is preferred)
Type of Vehicle Fuel Pump:
Electric Fuel Pump Operation with Ignition Switch ON and Engine OFF —
Details of Fuel System:
Comments
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 44
Data Sheet No. 3

Moving Barrier Data
Moving Barrier’s Test Weight:
Right Front _____kg Right Rear _____kg
Left Front _____kg Left Rear _____kg
Total Front Weight: _____kg Total Rear Weight _____kg
Total Test Weight _____kg
Tires (Mfr, line,

size):________________________________________________________
Recommended Maximum
pressure:_____________________________________________
Brake Abort system?(Yes/No):_______
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 45
Data Sheet No. 4

Post Test Data
TYPE OF TEST:
TEST DATE: ; TIME: ; TEMP.: °C
NHTSA NO.: ; VIN:
REQUIRED IMPACT VELOCITY RANGE: to km/h
ACTUAL IMPACT VELOCITY: (speed traps located within 1.5 m of impact plane)
Trap No. 1 = km/h Trap No. 2 = km/h
Average Impact Speed = km/h
STODDARD SOLVENT SPILLAGE MEASUREMENT:
A. From impact until vehicle motion ceases —
Actual = g Maximum Allowable = 28 g
B. For 5 minute period after vehicle motion ceases —
Actual = g Maximum Allowable = 28 g
C. For next 25 minutes —
Actual = g Maximum Allowable = 28 g/minute
D. Provide Spillage Details:
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 46
Data Sheet No. 5

STATIC ROLLOVER TEST DATA
REAR VIEW
0°/360 °
A. Test Phase = 0° to 90°
Determination of Stoddard Solvent Collection Time Period:
1. Rollover Fixture 90° Rotation Time = minutes, seconds
(Specified Range is 1 to 3
minutes)
2. FMVSS 301 Position Hold

Time = 5 minutes, 0 seconds
3. TOTAL = minutes, seconds
4. NEXT WHOLE MINUTE INTERVAL = minutes
Actual Test Vehicle Stoddard Solvent Spillage:

TP-301-03 Page 47
REAR VIEW
90 °
1. First 5 minutes from onset of rotation = g

(142 g allowed)
2. 6th minute = g
(28 g allowed)
3. 7th minute = g
(28 g allowed)
4. 8th minute = g
(28 g allowed)
Provide Details of Stoddard Solvent Spillage Locations —

TP-301-03 Page 48
REAR VIEW
90 °
B. Test Phase = 90° to 180°
Determination of Stoddard
Solvent Collection Time Period:
1. Rollover Fixture 90°

Rotation Time = minutes,
seconds
minutes)


TP-301-03 Page 49
180 °
REAR VIEW
Actual Test Vehicle Stoddard
Solvent Spillage:

(142 g allowed)
2. 6th minute = g
(28 g allowed)
3. 7th minute = g
(28 g allowed)
4. 8th minute = g
(28 g allowed)

TP-301-03 Page 50
180 °
REAR VIEW
C. Test Phase = 180° to 270°

seconds
minutes)


TP-301-03 Page 51
REAR VIEW
270 °
4. NEXT WHOLE MINUTE

INTERVAL = minutes

Solvent Spillage:

(142 g allowed)
2. 6th minute = g
(28 g allowed)
3. 7th minute = g
(28 g allowed)
4. 8th minute = g
(28 g allowed)

TP-301-03 Page 52
REAR VIEW
270 °
D. Test Phase = 270° to 360°

seconds
minutes)


TP-301-03 Page 53
REAR VIEW
0°/360 °
Solvent Spillage:

(142g allowed)
2. 6th minute = g
(28 g allowed)
3. 7th minute = g
(28 g allowed)
4. 8th minute (if required) = g

(28 g allowed)
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 54
15. DATA SHEETS....Continued
Data Sheet No. 6

SUMMARY OF FMVSS 212 DATA
DETAILS OF WINDSHIELD MOUNTING (method of retention, type of trim, etc.)
_____________________________________________________________________
_____________________________________________________________________
WINDSHIELD PERIPHERY:
Pretest Measurement — Right Side = inches
Left Side = inches
TOTAL = inches
Post Test Measurement — Right Side = inches
Left Side = inches
TOTAL = inches
NOTE: Post Test Measurement shall be minimum of 75% of Pretest Measurement for
vehicle NOT equipped with automatic front occupant restraints. Post Test Measurement
shall be a minimum of 50% for each side of the windshield for vehicles equipped with
automatic front occupant restraints.
TEMPERATURE OF WINDSHIELD MOLDING DURING TEST = ºF
AREA OF RETENTION FAILURES:
Indicate area of retention loss and width of molding on sketch shown on next page.
REMARKS:
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 55
INDICATE WIDTH OF MOLDING
Y D
C
ZERO POINT (0,0)
REMARKS:
RECORDED BY: ; DATE: ____________________
APPROVED BY: ___________________________

TP-301-03 Page 56
Data Sheet No. 7

SUMMARY OF FMVSS 219 DATA
METHOD OF ADHERING STYROFOAM TEMPLATE TO WINDSHIELD:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
SKETCH OF FRONT VIEW OF WINDSHIELD:
Provide all dimensions necessary to reproduce the protected area
Y
E F B
D X
LOWER EDGE OF PROTECTED ZONE
ZERO POINT (0,0)
AREA OF PROTECTED ZONE FAILURES:
A. Provide coordinates of the area that the protected zone template was penetrated
more than 0.25 inches by a vehicle component other than one, which is normally
in contact with the windshield
_______________________________________________________________________
TP-301-03 Page 57
B. Provide coordinates of the area beneath the protected zone template that the inner
surface of the windshield was penetrated by a vehicle component
_______________________________________________________________________
_______________________________________________________________________
REMARKS:
RECORDED BY: ; DATE: _____________________
APPROVED BY: ____________________________

TP-301-03 Page 58
16. FORMS
Forms, like Data Sheets, are provided as TOOLS to use in the exchange of data
between the COTR and the contractor. Forms, unlike Data Sheets, are not PART
of the Final Test Report. The contractor is not restricted from using other tools or
expanding the forms outlined in this section.
A. Form 1 - Vehicle Condition Report
A "Vehicle Condition Report" form shall be submitted to the COTR with the
copies of the Final Test Report (see example form). The first page of the
form shall be completed when the test vehicle arrives at the testing
laboratory. The second page of the form is completed after the test. The
forms shall be LEGIBLE (hand written forms are unacceptable) and
COMPLETE (all information requested is filled out).
B. Form 2 - Test Vehicle Information
A "Test Vehicle Information" form will be supplied by the COTR to the

contractor before testing preparation (see example form). Information on
this form is supplied by the automobile manufacturer to aid in the initial test
set-up and shall be considered as REFERENCE MATERIAL. After vehicle
preparation is complete, the Test Vehicle Information form shall be
discarded.
C. Form 3 - Laboratory Notice of Test Failure to OVSC
A Laboratory Notice of Test Failure form shall be submitted to the COTR

within 48 hours of an apparent test failure (see example form). The
completed form may be transmitted by fax, electronic mail or overnight
delivery.
TP-301-03 Page 59
16. FORMS....continued
FORM 1
Report of Vehicle Condition
CONTRACT NO. DTNH22- DATE:

FROM:
TO:
PURPOSE: ( ) Initial ( ) Received ( ) Present
Receipt via Transfer vehicle condition
MODEL YEAR/MAKE/MODEL/BODY STYLE:

MANUFACTURE DATE: NHTSA NO.: BODY COLOR:
VIN: GVWR GAWR (Fr) GAWR (Rr)
ODOMETER READINGS: ARRIVAL miles DATE:
COMPLETION miles DATE:

PURCHASE PRICE: $ DEALER'S NAME:
II ALL OPTIONS LISTED ON “WINDOW STICKER” ARE PRESENT ON THE TEST VEHICLE
II TIRES AND WHEEL RIMS ARE NEW AND THE SAME AS LISTED
II THERE ARE NO DENTS OR OTHER INTERIOR OR EXTERIOR FLAWS
II THE VEHICLE HAS BEEN PROPERLY PREPARED AND IS IN RUNNING CONDITION
II KEYLESS REMOTE IS AVAILABLE AND WORKING
II THE GLOVE BOX CONTAINS AN OWNER’S MANUAL, WARRANTY DOCUMENT, CONSUMER

INFORMATION, AND EXTRA SET OF KEYS
II PROPER FUEL FILLER CAP IS SUPPLIED ON THE TEST VEHICLE
II USING PERMANENT MARKER, IDENTIFY VEHICLE WITH NHTSA NUMBER AND FMVSS
TEST TYPE(S) ON ROOF LINE ABOVE DRIVER DOOR OR FOR SCHOOL BUSES, PLACE A
PLACARD WITH NHTSA NUMBER INSIDE THE WINDSHIELD AND TO THE EXTERIOR FRONT
AND REAR SIDE OF BUS
II PLACE VEHICLE IN STORAGE AREA
II INSPECT THE VEHICLE’S INTERIOR AND EXTERIOR, INCLUDING ALL WINDOWS, SEATS,
DOORS, ETC., TO CONFIRM THAT EACH SYSTEM IS COMPLETE AND FUNCTIONAL PER
THE MANUFACTURER’S SPECIFICATIONS. ANY DAMAGE, MISADJUSTMENT, OR OTHER
UNUSUAL CONDITION THAT COULD INFLUENCE THE TEST PROGRAM OR TEST RESULTS
SHALL BE RECORDED. REPORT ANY ABNORMAL CONDITION TO THE NHTSA COTR
BEFORE BEGINNING ANY TEST
TP-301-03 Page 60
REPORT OF VEHICLE CONDITION AT THE COMPLETION OF TESTING
LIST OF FMVSS TESTS PERFORMED BY THIS LAB:
VEHICLE NHTSA NO.
REMARKS:
Equipment that is no longer on the test vehicle as noted on previous page:
Explanation for equipment removal:
Test Vehicle Condition:
RECORDED BY: DATE:
APPROVED BY: DATE:
###############################################################################################
RELEASE OF TEST VEHICLE
The vehicle described above is released from to be delivered to
Date: Time: Odometer:
Lab Representative:
Signature Title
Carrier/Customer Representative:
Signature Date
TP-301-03 Page 61
FORM 2
TEST VEHICLE INFORMATION
VEHICLE MODEL YEAR/MAKE:
MODEL/BODY STYLE:
1. NOMINAL DESIGN RIDING POSITION –
DEGREES
UPRIGHT POSITION
SEAT BACK
INCLINOMETER
SEAT CUSHION ADJUSTER
LEFT SIDE VIEW
FRONT SEAT ASSEMBLY

For adjustable driver and passenger seat backs.
Please describe how to position the inclinometer to measure the seat back angle.
Include description of the location of the adjustment latch detent if applicable.
Indicate, if applicable, how the detents are numbered
(Is the first detent "0" or "1"?).
Seat back angle for driver's seat =

°
Measurement Instructions:
Seat back angle for passenger's seat = °

Measurement Instructions:
TP-301-03 Page 62
2. SEAT FORE & AFT POSITIONS –

Provide instructions for positioning the driver and front outboard passenger seat(s)
in the center of fore and aft travel. For example, provide information to locate the
detent in which the seat track is to be locked.
Positioning of the driver's seat:
Positioning of the passenger's seat (if applicable):
3. FUEL TANK CAPACITY DATA –
3.1 A. "Usable Capacity" of standard equipment fuel tank =

gallons.
B. "Usable Capacity" of optional equipment fuel tank =

gallons.
C. "Usable Capacity" of vehicle(s) used for certification testing to requirements

of FMVSS 301 =
gallons.
Operational Instructions:
3.2 Amount of Stoddard solvent added to vehicle(s) used for certification

test(s) = gallons
3.3 Is vehicle equipped with electric fuel pump? Yes- ; No-
If YES, explain the vehicle operating conditions under which the fuel pump will
pump fuel.
4. STEERING COLUMN ADJUSTMENT
Steering wheel and column adjustments are made so that the steering wheel hub
is at the geometric center of the locus it describes when it is moved through its full
range of driving positions. If the tested vehicle has any of these adjustments, does
your company use any specific procedures to determine the geometric center.
Operational Instructions:
TP-301-03 Page 63
FORM 3
LABORATORY NOTICE OF TEST FAILURE TO OVSC
TEST DATE:
LABORATORY:
CONTRACT NO.: ; DELV. ORDER NO.:
LAB PROJECT ENGINEER'S NAME:
TEST VEHICLE YEAR/MAKE/MODEL/BODY STYLE:
VEH. NHTSA NO.: ; VIN:
MFR:
TEST FAILURE DESCRIPTION:
FMVSS REQUIREMENT, PARAGRAPH S :
NOTIFICATION TO NHTSA (COTR):
DATE: ; BY:
REMARKS:
TP-301-03 Page 64
APPENDIX 1
ANTI-SIPHONING DEVICE FOR ALCOHOL FUEL VEHICLES
APPLICABLE ONLY TO THOSE VEHICLES TYPES THAT ARE CURRENTLY

SUBJECT TO FMVSS 301 AND THAT ARE DESIGNED TO OPERATE WITH AT LEAST
20 PERCENT ALCOHOL FUEL CONTENT.
A1.1 TEST EQUIPMENT DESCRIPTION
The following is a list of the minimum suggested test equipment needed to perform
the anti-siphoning test for alcohol fuel vehicles (S6.6).
A straight vinyl plastic or rubber hose of 120 centimeters (cm), +0.00, -0.60
(47.20 inches, +0.00, -0.25) length. The hose will have an outside diameter
of 5.20 millimeters (mm), +0.00, -0.26 (0.20 inches, +0, -0.01).
A1.2 DEFINITIONS
ALCOHOL FUEL VEHICLES
Each vehicle manufactured to operate on an alcohol fuel (e.g., methanol, ethanol)

or a fuel blend containing at least 20 percent alcohol fuel.
A1.3 COMPLIANCE TEST EXECUTION
Position the test vehicle on a level surface, fill the fuel tank with Stoddard solvent
to between 90 to 95 percent of its useable capacity. Insert one end of the test
hose into the fuel filler neck and determine whether the hose will pass through the
anti-siphoning device and reach the solvent. Insert the test hose as far into the
fuel filler neck as possible or until it is completely within the fuel filler neck or
blocked by the anti- siphoning device. During insertion, keep the test hose
concentric with the opening of the anti-siphoning device, if possible.
Measure the length of any remaining portion of the test hose outside of the fuel
filler neck.
Record the measurement in Data Sheet 1.
Pull the test hose out of the fuel filler neck carefully for examination. If there is
evidence that the hose had contacted the surface of the Stoddard solvent in the
tank, then measure the length of the hose that was submerged in the solvent.
The vehicle fails the test if there is evidence that the hose end contacted the
surface of the solvent in the tank.
TP-301-03 Page 65
APPENDIX 1....continued
DATA SHEET A1.1

ANTI-SIPHONING DEVICE FOR ALCOHOL FUEL VEHICLES
VEH. MOD YR/MAKE/MODEL/BODY:
VEH. NHTSA NO.: ; VIN:
VEH. BUILD DATE: ; TEST DATE:
TEST LABORATORY:
OBSERVERS:
1. Provide a description of the anti-siphoning device if possible.
2. Did the test hose pass through the anti-siphoning device opening?
Yes- No-
3. The test hose length outside of the fuel filler neck at maximum insertion:
Length = cm
4. The maximum inserted test hose length is (120.00 cm - measurement from item
3):
Length = cm
5. Was there evidence that the test hose contacted the surface of the Stoddard fluid
in the fuel tank of the test vehicle?
Yes- (Fail) No- (Pass)
6. Measure the length of the portion of the hose that was submerged in the Stoddard
solvent:
Length = cm
TP-301-03 Page 66
APPENDIX 2
MODIFIED FMVSS 301 TEST, REAR IMPACT ONLY
FOR THE PURPOSE OF ACQUIRING INFORMATION FOR APPLIED RESEARCH,

FMVSS 301, FUEL SYSTEM INTEGRITY TEST - REAR IMPACT, IS MODIFIED FOR
EACH INSTRUMENTED DUMMY WITH THE FOLLOWING ADDITIONAL TEST AND
DATA ACQUISITION REQUIREMENTS:
A2.1 TEST EQUIPMENT DESCRIPTION
The following is a list of the minimum additional test equipment needed to perform
the modified FMVSS 301 test.
A. A anthropomorphic test dummy, Part 572E (Hybrid III), Part 572O (Hybrid III),
Thor, or BioRid etc.
B. Sensor to measure head rotation directly or calculated from angular velocity for
the test dummy specified above.
C. Sensor to measure chest rotation directly or calculated from angular velocity for
the test dummy specified above.
D. Load cell to measure lower neck loads.
E. Lower neck accelerometer for the test dummy specified above.
F. Sensor to measure vehicle rotation directly or calculated from angular velocity.
G. SAE J826 manikin.
H. Head Restraint Measuring Device (Insurance Corporation of British Colombia
(ICBC) machine).
I. Sensors to measure rotation for both the left and right side seat back directly or
calculated from angular velocity.
J. Head Center of Gravity (C.G.) Triaxial Accelerometers for the test dummy
specified above.
K. Chest C.G. Triaxial Accelerometers for the test dummy specified above.
L. Pelvis C.G. Triaxial Accelerometers for the test dummy specified above.
M. Load cell to measure upper neck loads.
N. Load cells to measure femur loads.
O. Sensors to measure vehicle acceleration, passenger seat belt motion (playout),
and passenger seat belt load.
P. Data recording equipment having sufficient channels to record the necessary
time history. Each data channel shall consist of a sensor, signal conditioner,
data acquisition device, and all interconnecting cables and shall conform to the
requirements of SAE Recommended Practice J211.
TP-301-03 Page 67
The following is a list of the minimum additional test equipment needed to perform
the optional seat translation device for the modified FMVSS 301 test.
A. 2 String potentiometers
B. 2 Rotary potentiometers
A2.2 ADDITIONAL INSTRUMENTATION
Instrument the anthropomorphic test dummy as follows (Actual dummy and type of
sensors used will be chosen in coordination with OVSC and OCR):
A. Head rotation about the y-axis (GFE*).

B. Chest rotation about the y-axis (GFE*).
C. Head C.G. Triaxial Accelerometers
D. Chest C.G. Triaxial Accelerometers
E. Pelvis C.G. Triaxial Accelerometers
F. Lower neck accelerometer.
G. Left femur load cell, single axis
H. Right femur load cell, single axis
I. Upper Neck
1. 3-axis Neck Force Transducers (GFE*)
2 3-axis Neck Moment Transducers (GFE*)
J. Lower Neck
1. 3-axis Neck Force Transducers (GFE*)
2 3-axis Neck Moment Transducers (GFE*)
* Government Furnished Equipment
Dummy calibration, according to the appropriate Dummy Performance Calibration

Procedure, shall be performed prior to the start of testing, after every fifth test, and
at the completion of testing.
Instrument the test vehicle to record the following:
A. Passenger left seat back rotation about the y-axis (GFE*)

B. Passenger right seat back rotation about the y-axis (GFE*)
C. Passenger door sill rotation about the y-axis (GFE*)
D. Primary and redundant accelerometers to record occupant compartment
acceleration
E. Driver seat belt motion (playout)
F. Driver seat belt load
NOTE: Location of transducers will be determined in coordination with the Office

of Vehicle Safety Compliance (OVSC) and the Office of Crashworthiness
Research (OCR).
TP-301-03 Page 68
A.2.3 ONBOARD CAMERA REQUIREMENT
One high speed digital camera (1,000 frames/second) placed on/in the vehicle to
acquire improved film coverage of seat/dummy/belt
dynamics in a rear crash. The resolution of the high speed digital camera shall
meet the specifications from section 9.2 Camera Coverage of this test procedure.
Time zero impact mark must be registered on the high speed video to indicate
when contact with the barrier is made in a crash test. Actual camera location will
be chosen in coordination with OVSC and OCR.
A.2.4 REPORTS AND ELECTRONIC TEST DATA
A. Plots to be included in test report —

Lower neck acceleration vs. time
Lower neck X,Y,Z force vs. time
Lower neck X,Y,Z moment vs. time
Vehicle angular velocity vs. time (if applicable)
Vehicle rotation vs. time
Left side seat back angular velocity vs. time (if applicable)
Left side seat back rotation vs. time
Head angular velocity vs. time (if applicable)
Head rotation vs. time
Chest angular velocity vs. time (if applicable)
Chest rotation vs. time
B. Measurements of the head restraint height and backset and note if the
restraint locks in the adjusted position.
C. Note any deformation of the seat and attachment points to the floor
D. Note the type of recliner mechanism and any deformation of the recliner
mechanism. Also note if there is a recliner mechanism on each side.
E. One set of still photos in digital format (JPEG). The JPEG files shall have
the same naming convention as used on the photos in the final report.
F. One final report in PDF format.
Additional information included in reports and electronic test data for the optional
seat translation measurement device.
A. Plots to be included in test report –

String displacement vs. time for the left side of the seat from the string
potentiometer
Rotation vs. time for the for the left side of the seat from the rotary
potentiometer
String displacement vs. time for the right side of the seat from the string
potentiometer
Rotation vs. time for the for the right side of the seat from the rotary
potentiometer
Displacement in the x-direction vs. time for the point of interest on the seat
B. Provide data sheet of the test setup of the optional seat translation
measurement device.
TP-301-03 Page 69
A2.5 FRONT SEAT CUSHION ADJUSTEMENT
Adjustable front seat are adjusted according to the test dummy used. For the Part
572 tests dummies shall be positioned according the procedure in Procedure
TP208-12 dated January 14, 2003. The final position of the seat cushion will be
determined in coordination with the Office of Vehicle Safety Compliance (OVSC)
and the Office of Crashworthiness Research (OCR).
A2.6 FRONT SEAT BACK ADJUSTEMENT
Place the front seat back to give a torso angle of 25 degrees + 1 degrees as
measured by the SAE J826 manikin (not furnished by the government). The final
seat back torso angle will be determined in coordination with the Office of Vehicle
Safety
Compliance (OVSC) and the Office of Crashworthiness Research (OCR).
A2.7 HEAD RESTRAINT POSITIONING AND MEASUREMENTS
The head restraint position will be determined in coordination with the Office of
Vehicle Safety Compliance (OVSC) and the Office of Crashworthiness Research
(OCR). The head restraint height and backset shall be measured according to the
NPRM for FMVSS No. 202 (66 FR 968 – January 4, 2001). The ICBC machine
will be government furnished equipment (GFE).
A2.8 DUMMY POSITIONING AND MEASUREMENTS
Anthropomorphic Test Dummy shall be placed in the passenger location and

positioned with the appropriately procedure defined in TP208-12 dated January
14, 2003. The test lab shall provide measurements of the dummy in accordance
with Data Sheet 35 of TP208-12 dated January 14, 2003. The final position
procedure of the dummy will be determined in coordination with the Office of
(OCR).
A2.9 ADDITIONAL TARGETS
Location of additional targets will be determined in coordination with the Office of

(OCR).
A2.10 ELECTRONIC DATA SUBMISSION FOR ALL STANDARDS
An electronic data submission (CDs/diskettes), formatted in accordance with the

NHSTA EV5 data format as specified in the Version 5 Test Reference Guide, Volume
1: Vehicle Tests (VTRG), shall be required for each test conducted for OVSC. Copies
of the guide may be downloaded from the web site, http://www-
nrd.nhtsa.dot.gov/software/entree/index.htm
TP-301-03 Page 70
The initial electronic data submission post-test will contain specification and
measurement data in this EV5 format. Subsequent submission of the digital photos
(JPEG), AVI, and the PDF copy of the final report shall also be prepared in accordance
with the specifications for submission of these deliverables as defined in the Guide
(VTRG).
Each submission shall include the raw sensor outputs measured to determine
compliance to the standard, such as acceleration, force, displacement, etc.
Any questions concerning preparation of the electronic data submission shall be

directed to:
Barbara Hennessey
US/DOT
NHTSA/NVS-321
PH: 202-366-4714
Fax: 202-366-3505
e-mail: barbara.hennessey@nhtsa.dot.gov
A2.11 OPITIONAL SEAT TRANSLATION MEASUREMENT DEVICE
The seat translation measurement device (STMD) consists of a cross bar that
attaches to the roof of the vehicle and extension bars mounted to the sides of the
seat. For each side of the seat a string pot is attached to the cross bar and the
string is attached to the extension bar from the seat. At the location of the string
and the extension from the seat is a rotary pot. Details on the mounting and use
of the STMD will be determined in coordination with the Office of Vehicle Safety
Compliance (OVSC) and the Office of Crashworthiness Research (OCR). After
positioning the dummy measure the position of string at the cross bar attached to
the roof, the position of the rotary potentiometer and point of interest on the seat.
A2.12 OPITIONAL ADDITIONAL DUMMY AND VEHICLE CHANNELS
Location of additional channels will be determined in coordination with the Office of

(OCR).
A2.13 GOVERNMENT TEST INFORMATION SHEET
The Government will furnish an information sheet when this option is exercised for
each individual test or series of tests. At a minimum the information sheet will
include the following:
TP-301-03 Page 71
A. Selection dummy and types of sensors

B. Location of transducers
C. Position of seat cushion
D. Final seat back torso angle
E. Head restraint position
F. Final position procedure for the dummy
G. Camera location(s)
H. Additional targets
I. Details on mounting the STMD
J. Location of additional channels
K. Pre and Post seat back angle
TP-301-03 Page 72
REPORT OF VEHICLE CONDITION AT THE COMPLETION OF TESTING
CONTRACT NO.: DTNH22- DATE: _________________
FROM:
TO:
The following vehicle has been subjected to compliance testing for FMVSS No. _______________________
The vehicle was inspected upon arrival at the laboratory for the test and found to contain all of the equipment listed
below. All variances have been reported within 2 working days of vehicle arrival, by letter, to the NHTSA Industrial
Property Manager (NAD-30), with a copy to the OVSC COTR. The vehicle is again inspected, after the above test
has been conducted, and all changes are noted below. The final condition of the vehicle is also noted in detail.
MODEL YEAR/MAKE/MODEL/BODY STYLE: ______________________________________________________
NHTSA NO.: BODY COLOR: VIN: _____________________________
ODOMETER READINGS: ARRIVAL - miles DATE - _______________________
COMPLETION - miles DATE - _______________________
PURCHASE PRICE: $ DEALER'S NAME: ________________________________________
ENGINE DATA: Cylinders Liters Cubic Inches
TRANSMISSION DATA: Automatic Manual No. of Speeds
FINAL DRIVE DATA: Rear Drive Front Drive 4 Wheel Drive
TIRE DATA: Size - Mfr. - ______________________________________
CHECK APPROPRIATE BOXES FOR VEHICLE EQUIPMENT:
Air Conditioning Traction Control Clock
Tinted Glass All Wheel Drive Roof Rack
Power Steering Speed Control Console
Power Windows Rear Window Defroster Driver Air Bag
Power Door Locks Sun Roof or T-Top Passenger Air Bag
Power Seat(s) Tachometer Front Disc Brakes
Power Brakes Tilt Steering Wheel Rear Disc Brakes
Antilock Brake System AM/FM/Cassette Radio Other-
LIST OTHER PERTINENT OPTIONAL EQUIPMENT ON NEXT PAGE (REMARKS SECTION)

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TP-301-04

January 17, 2007

U.S. DEPARTMENT OF TRANSPORTATION

2. GENERAL REQUIREMENTS ........................................................................................ 2

5. TEST SCHEDULING AND MONITORING..................................................................... 3

6. FACILITY AND EQUIPMENT......................................................................................... 3

7. GOVERNMENT FURNISHED PROPERTY (GFP) ........................................................ 8

8. CALIBRATION OF TEST INSTRUMENTS .................................................................... 9

9. PHOTOGRAPHIC DOCUMENTATION ......................................................................... 10

11. PRETEST REQUIREMENTS......................................................................................... 19

12. TEST EXECUTION ........................................................................................................ 20

13. TEST DATA DISPOSITION ........................................................................................... 31

14. REPORTS ...................................................................................................................... 31

14.1. MONTHLY STATUS REPORTS ........................................................................ 31

14.2. APPARENT NONCOMPLIANCE ....................................................................... 32

14.3. FINAL TEST REPORTS..................................................................................... 32

14.3.1. COPIES .................................................................................................. 32

14.3.3. FIRST THREE PAGES........................................................................... 33

14.3.4. TABLE OF CONTENTS.......................................................................... 37

15. DATA SHEETS .............................................................................................................. 41

16. FORMS .......................................................................................................................... 58

APPENDIX 1, Anti-Siphoning Device for Alcohol Fuel Vehicles .................................... 64

APPENDIX 2, Modified FMVSS 301 Test, Rear Impact Only ........................................ 66

TEST PROCEDURE FMVSS 301

REV. EFFECTIVE DESCRIPTION

00 04/26/89 No Revision 04/26/89 Original release signed by O.D.

01 3/28/94 3/28/94 Add 2 appendices

02 11/8/94 11/8/94 Add lateral camera requirements

03 2/28/03 63FR28922 5/27/99 Conversion to metric and minor revisions

04 1/17/07 1/17/07 Reference 214 for lateral impact

FMVSS 301 — FUEL SPILLAGE — BARRIER CRASH

FMVSS 301 — FUEL SPILLAGE — ROLLOVER

NOTE: NO INDIVIDUALS, OTHER THAN CONTRACTOR PERSONNEL DIRECTLY

5. TEST SCHEDULING AND MONITORING

Scheduling of vehicle tests shall be adjusted to permit vehicles to be tested to other

6. FACILITY AND EQUIPMENT

6.1 IMPACT TEST FACILITY

TYPICAL BARRIER IMPACT

6.2 IMPACT SPEED MEASUREMENT SYSTEM

Test vehicle or moving barrier impact speed or velocity shall be measured by 2

6.3 MOVING BARRIER

1. A common carriage constructed in accordance with Figure 1 of

3. An impact surface that is a vertical, rigid, flat rectangle, 1981 mm (78

horizontal and 127 mm (5 inches) above the ground surface. The

4. A braking device capable of stopping it.

5. Mounting brackets necessary to accommodate an overhead camera

6. A weight distribution of 408.2 ± 11.3 kg at each rear wheel and 499 ±

7. Pneumatic tires on all wheels, P205/75R15, inflated to 200 +/- 21

Fig 1 - COMMON CARRIAGE FOR MOVING BARRIERS

DIMENSIONS FOR COMMON CARRIAGE FOR MOVING BARRIERS

Note - Dimensions shall be within 5% of the specifications listed above

6.4 PHOTOGRAPHIC PIT

6.5 STATIC ROLLOVER DEVICE

6.6 WEIGHING SCALES

6.7 TEST SURFACE AND TEST PAD AREA

6.8 TOW ROAD

6.9 TOW AND GUIDANCE SYSTEM

6.10 TEST ABORT SYSTEM

8. CALIBRATION OF TEST INSTRUMENTS

B. All measuring instruments and standards shall be calibrated by the

C. All measuring and test equipment and measuring standards shall be

(1) Date of calibration